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CHIMNEY AND VENT PIPE CONNECTION .......................................................................................................................................................7-9
Checking Chimney....................................................................................................................................................................................................8
Minimum Vent Pipe Clearance................................................................................................................................................................................8
Removing Existing Boiler from Common Venting System....................................................................................................................................9
OPTIONAL HORIZONTAL VENTING WITH POWER VENTER ....................................................................................................................9-10
GAS SUPPLY PIPING ..........................................................................................................................................................................................10-11
Checking Gas Supply .............................................................................................................................................................................................10
Connecting Gas Piping......................................................................................................................................................................................10-11
Checking Gas Piping..............................................................................................................................................................................................11
ELECTRICAL WIRING..............................................................................................................................................................................................12
Electric Power Supply............................................................................................................................................................................................11
Installing Thermostat..............................................................................................................................................................................................11
Wiring Diagram......................................................................................................................................................................................................12
SEQUENCE OF OPERATION...................................................................................................................................................................................11
EQUIPMENT AND OPTIONAL ACCESSORIES ..............................................................................................................................................13-14
Relief Valve............................................................................................................................................................................................................13
Expansion Tank (Optional) ....................................................................................................................................................................................13
Diaphragm-Type Expansion Tank (Optional)........................................................................................................................................................13
Air-Eliminating Fitting (Air Purger) (Optional)....................................................................................................................................................13
Main Air Vent for Downflow Systems or Diaphragm-Type Expansion Tank (Optional) ..................................................................................13
Automatic Fill Valve (Optional) ............................................................................................................................................................................13
Drain Valve.............................................................................................................................................................................................................13
Water Temperature Control....................................................................................................................................................................................13
Circulating Pump....................................................................................................................................................................................................14
Blower (Draft Inducer)...........................................................................................................................................................................................14
Pressure Switch.......................................................................................................................................................................................................14
Rollout Switch (Flame Rollout Safety Shutoff) ....................................................................................................................................................14
STARTING BOILER...................................................................................................................................................................................................14
How a Hot Water System Operates.......................................................................................................................................................................14
Filling System with Water......................................................................................................................................................................................14
FOR YOUR SAFETY READ BEFORE OPERATING.......................................................................................................................................14-15
GAS VALVE OPERATING INSTRUCTIONS.........................................................................................................................................................15
CHECKING AND ADJUSTING ................................................................................................................................................................................16
Gas Valve Safety Shutdown Test ..........................................................................................................................................................................16
Pilot Burner Adjustment.........................................................................................................................................................................................16
Main Burner Air Adjustment .................................................................................................................................................................................16
Limit Controls Adjustment.....................................................................................................................................................................................16
Thermostat Heat Anticipator Adjustment ..............................................................................................................................................................16
Safety Controls Check............................................................................................................................................................................................16
MAINTAINING BOILER......................................................................................................................................................................................17-18
Burners....................................................................................................................................................................................................................17
Relief Valve............................................................................................................................................................................................................17
Expansion Tank ......................................................................................................................................................................................................17
Boiler Flue Passages...............................................................................................................................................................................................17
Vent Pipe.................................................................................................................................................................................................................17
Water System..........................................................................................................................................................................................................17
Cleaning Boiler and Burners.............................................................................................................................................................................17-18
Blower.....................................................................................................................................................................................................................18
SERVICE HINTS ........................................................................................................................................................................................................19
REPAIR PARTS.....................................................................................................................................................................................................20-23
SAFETY CONSIDERATIONS
Installing and servicing heating equipment can be hazardous due to gas and electrical components. Only trained and qualified personnel should
install, repair, or service heating equipment. Untrained personnel can perform basic maintenance functions such as maintaining water level. All
other operations must be performed by trained service personnel. When working on heating equipment, observe precautions in literature, on tags,
and on labels attached to or shipped with unit and other safety precautions that may apply.
Follow all safety codes. In the United States, follow all safety codes including the National Fuel Gas Code (NFGC) NFPA 54-1999/ANSI
Z223.1-1999. In Canada, refer to the current edition of the National Standard of Canada CAN/CGA-B149.1- and .2-M95 Natural Gas and Propane
Installation Codes (NSCNGPIC). Wear safety glasses and work gloves. Have fire extinguisher available during start-up and adjustment procedures
and service calls.
Recognize safety information. This is the safety-alert symbol
. When you see this symbol on unit or in instructions and manuals, be alert to
potential for personal injury.
Understand the signal words DANGER, WARNING, CAUTION, and NOTE. These words are used with safety-alert symbol. DANGER identifies
most serious hazards which will result in severe personal injury or death. WARNING signifies hazards which could result in personal injury or
death. CAUTION is used to identify unsafe practices which would result in minor personal injury or product and property damage. NOTE is used
to highlight suggestions which will result in enhanced installation, reliability, or operation.
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